Chromium–Aluminum Coatings for Oxidation Protection of Titanium–Aluminum Intermetallic Alloys

Abstract

This article explores the utilization of cathodic-arc deposition Cr-Al overlay coatings as oxidation protection for Ti-Al-Nb intermetallic alloys. The primary objective is to investigate PVD Al-Cr coatings deposited via cathodic-arc deposition without subsequent vacuum annealing. The microstructure, phase, and chemical composition of the coatings were characterized using scanning electron microscopy, energy-dispersive X-ray spectroscopy, and X-ray diffraction analysis. Isothermal exposure of samples in a laboratory air furnace was conducted, revealing the efficacy of Cr-Al coatings in protecting the Ti49-11Al-40Nb-1.5Zr-0.75V-0.75Mo-0.2Si (mass%) intermetallic alloy VTI-4 against oxidation. The findings highlight that the as-deposited coatings possess a layered structure and contain Al-Cr intermetallics. Post-exposure to the furnace without prior vacuum annealing results in coatings exhibiting a porous microstructure, raising concerns regarding oxidation protection. This investigation of Cr-Al coatings on a VTI-4 alloy substrate yields valuable insights into their nanolaminate structure and challenges associated with aluminum droplet fractions. The proposed additional vacuum heat treatment at 650 °C for 500 h effectively homogenizes the coating, leading to predominant Cr2Al and Ti-Al phases. Additionally, the formation of diffusion layers at the “coating–substrate” interface and the presence of oxide barriers contribute to the coatings’ heat resistance. Our research introduces possibilities for tailoring coating properties for specific high-temperature applications in aerospace, energy, or industrial contexts. Further refinement of the heat treatment process offers the potential for developing advanced coatings with enhanced performance characteristics.